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Kitchen Equipment Care:

Maintenance Helps Increase Your Sustainability and

I Y B tt LiImproves Your Bottom Line

Terry AndersonTechnician Support Supervisor

Ecolab, Equipment Care

How to make the most of your kitchen environment

Reduce Energy Costs

Want to make your business sustainable?

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Preventative Maintenance

Increase Operational Efficiency

Ensure Food Safety

One of the most lucrative opportunities to cut energy costs and promote operational efficiency is PREVENTATIVE MAINTENANCE.

Cut savings by 10% per year!

How to make the most of your kitchen environment

Cut Energy Consumption $

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Extend Equipment Life $Food Safety $

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Cut Energy Consumption

Restaurants Can Make a Difference

• Restaurants use 5 times more energy 

Restaurants are Big Users of Energy

5 Major Ways Restaurants Consume Energy

times more energy per square foot than other commercial buildings

• Energy costs rising at a rate of 6‐8% per year

• Focus your energy‐savings efforts in the kitchen

Source: Food Service Technology Center

Reducing Rising Energy Costs

• Energy costs continue to rise at rates higher than nominal restaurant growth

Utility Costs Represent 3-4% of Sales for an Average

Restaurant

growth10% in the past few years

• Preserve your profits by making your operation more sustainable

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Diligent Maintenance Pays Off

PreventativeMaintenance adds up to total savings• Basic maintenance can 

reduce your carbon reduce your carbon footprint

• Saving up to $500 or more a year in energy costsAND

• Helping to avoid costlyequipment downtime

Reduce Frequency of Repairs

Frequency of Repairs with PM Program

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Less visits = Less carbon emissionsLess visits = Increased ROI

What to Consider in a Proactive Care Plan

• Age and use of the equipment• Even Energy Star certified equipment needs to be calibrated to run at peak performance

• Recent repairs performed

• How often complete cleanings are How often complete cleanings are performed

• Pay Off

• Less energy used, adds money to your bottom line

• Less energy used means fewer carbon emissions

Good for you and the environment

Key InsightThe EPA estimates that by cutting energy costs by 20%, profits would increase by 30% or more

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Proactive Cooler Maintenance

• A poorly maintainedcooler increases the stress on the cooling system – requiring more energy to operate– shortening the life of the equipment

• Equivalent to the amount of carbon sequestered annually by  1 acre of pine or fir forests

Refrigerator/Freezer Opportunities

• Defrosting is an intensive but necessary process 

• Optimizing cycle times and calibrate to defrost as needed 

• Repair or replace worn door seals and hinges – ensuring a airtight door sealg g g

• Clean evaporator and condenser coils and ensure proper airflow.

• Install strip curtains on walk‐in boxes as insurance against propped‐open doors.

• Check and properly set thermostats and time clocks on all refrigeration equipment

Inefficiencies like these can lead to increased energy usage, breakdown 

or even failure

Broiler Savings Opportunity

• It is estimated that up to 80% of the $10 Billion spent on energy on U.S. restaurants is restaurants is wasted

• Reducing broiler “ON” time by 1 hour each day translates to greenhouse gas emissions avoided • Equivalent to 

recycling .65 tons of waste

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Warewashing Savings Opportunities

• Install a low‐flow pre‐rinse spray valve at the dish station

• Technologically advanced rinse‐spray nozzles are available that can save restaurants more than 

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50% in rinse water and energy costs

• Conduct a regular thermostat check on warewashers and reset them to the correct operating temperature when necessary

• Check rise pressure to ensure it uses only the pressure recommended

Cooking Savings Opportunities

• Properly adjust standing pilot lights on appliances like range tops

• Control appliance “on” time with a start‐up and shut‐down schedule and use timed controls vs. manual settings

• Maintain appliances, including ensuring ovens are cooking at 

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g g gthe proper temperature and that control panels on ovens and steamers are operating correctly

Preventative MaintenanceYour Ticket to Energy Savings and Sustainability

Proactive Care helps you achieve:

• A lower carbon footprint• Energy savings

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Improve Operational Efficiency

Life Extension = Cost Savings & Sustainability

• Industry recognizes that proactive maintenance programs increase equipment life by 6‐12 months

Proactive Maintenance Extends Equipment Life

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p g q p yNAFEM life cycle analyzes equipment life expectancies and total cost of ownership

• Longer equipment properly, calibrated, equipment saves energy and replacement/disposal  costs

• Mold in ice bin causing possible cross contamination and poor taste quality

• Water trough clogged with mold and scale causing inefficient operation of ice machine

• Ice thickness probe scaled up with lime causing frozen 

Ice Machine Operating Problems Ice Machine

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• Ice thickness probe scaled up with lime causing frozen evaporators and machine to not to operate correctly

• Dirty condenser coils cause inefficient operations and long term damage to the equipment

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• Highlights of prescheduled Performance Check services• Check compressor discharge line to ensure operating 

temperature is within specification• Clean coils and sanitize ice bins• Delime ice machine thoroughly

f

Performance CheckIce Machine

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• Change water filters regularly• On‐site kitchen staff training on regular equipment cleaning 

procedures

Ensure supply of clean, safe iceExtend lifespan of ice machineImprove operating efficiency

• Thermocouple and thermopile damages that lead to inaccurate frying temperatures, which results in inconsistent food quality and/or short cooking oil life

• Moisture and grease built up within electronic controls which cause premature fryer failures

• Inefficient oil filtration system leading to accelerated oil 

Fryer Operating ProblemsFryer

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• Inefficient oil filtration system leading to accelerated oil breakdown and waste

Performance CheckFryer

• Highlights of prescheduled Performance Check services• Check all common failure points such as electric element voltage,

contactor voltage, thermocouple integrity, and the voltage of other areas where power may be failing

• Thorough check and clean of oil filtration system to fully realize its benefits

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Make quality and safe fried foodSave energy and cooking oilExtend fryer lifespanIncrease uptime

• On-site kitchen staff training on regular equipment cleaning procedures

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Combi Oven / Steamer Operating Problems Combi Oven

• Scale buildup in steam generator results in operating inefficiency, longer cook/recovery times and long term damage to the steamer

• Temperature probes are covered in scale and do not allow the unit to heat properly

• Moisture penetration that causes electrical failures on fans, lights, or timers

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or timers

Performance CheckCombi Oven

• Highlights of prescheduled Performance Check services• Descale of boiler and clean probes• Timer calibration or replacement• Check on electric element to avoid power failures• Change out water filters regularly

• On-site kitchen staff training on regular equipment cleaning

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On site kitchen staff training on regular equipment cleaning procedures

Save energy and cooking timeExtend equipment lifespanIncrease equipment uptime

Refrigerator Operating Problems Refrigerator

• Clogged or blocked condensers cause increased energy consumption and trouble in maintaining temperature

• Debris caught in the condenser or evaporator fan causes serious damage to the unit

• Poor gasket sealing result in loss of cooling, increasing energy consumption and food safety risks

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consumption and food safety risks

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Performance CheckRefrigerator

• Highlights of prescheduled Performance Check services• Clean and check all condenser and evaporator coils• Check door gaskets and all door hinges for proper seal and

operating• Check temperature of compressor discharge line to ensure 

operating temperature is within specification• Check amperage and voltage to name plate specifications

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• Check amperage and voltage to name plate specifications

Improve energy efficiencyReduce food safety risksExtend equipment lifespanIncrease equipment uptime

Preventative MaintenanceYour Ticket to Operational Efficiency

Proactive Care helps you achieve:

• Operational efficiency

• Extended equipment life

FOOD SAFETY

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Where Was Contaminated Food Consumed?

Restaurant or deli23%

Rural family 

Make‐shift cafeteria

4%

Street vender2%

Other*3%

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Fast food service

2%

Private home24%Company 

cafeteria15%

School17%

Rural family banquet

10%

*< 1% of outbreaks•Adapted from: Xue and Zhang 2013 Food Control 30 (2013):311‐317

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Food at room temp. for several hours

X-contamination from raw ingredient

Bare hand contact

Handling by infected person

Contributing Factors to Restaurant Outbreaks

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0 20 40 60 80

Inadequate cleaning of equipment

Gloved-hand contact

Preparing food >12hr in advance

Raw product or ingr of animal origin

p

Percent of OutbreaksHedberg et al. 2006 JFP 69:2697

ContaminationGrowthSurvival (all <5%)

CDC Risk Factors for Foodborne Illness

Poor Personal 

Hygiene, 25%

Contaminated equipment/   

Unsafe Source, 10%

FEBRUARY 16, 2014 30 Adapted from CDC 2013. Appendix MMWR 62(SS02);1-34

Other, 4%

Inadequate Cooking, 9%

Improper Holding, 31%

q penvironment, 

20%

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1. Food at room temp for several hours—29% 2. Bare‐handed contact by food handler—25% 3. Inadequate cleaning of equipment—22%4. Handling by infected person or carrier—20%

Top 10 Factors Contributing to US Foodborne Illness 1998-2002

Contamination dominated!

Contamination

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4. Handling by infected person or carrier 20%5. Inadequate cold‐holding temperature—19%6. Cross contamination from raw animal 

products—12%7. Insufficient cooking—12%8. Raw ingredients contaminated by animal or 

environment—11%9. Slow cooling—11%10. Inadequate hot holding time/temperature—10%

Growth

Survival

Solutions for Foodborne Illness Contributing Factors

• Contamination prevention

• Hand care programs• Cleaning & sanitation 

products and services• Supply chain 

• Growth prevention• Thermometers• Date labels• [Remote temperature 

monitoring]

• Survival preventionSupply chain antimicrobial treatments for meat, poultry, and produce

• Color coded equipment• Pest elimination• [Hand care compliance]

• Survival prevention• Thermometers

• Overall• Food safety audits• Food safety training• Equipment maintenance

• Clean and sanitize all food contact surfaces 

How to prevent foodborneillness?

• Monitor holding, time and temperature of 

Clean and monitor the performance of your equipment

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food contact surfaces and equipment especially after changing from poultry to red meat

• Watch for buildup beneath cutting table top surfaces and other equipment

and temperature of freezer units

• Check refrigeration on a frequent basis to ensure that it is working properly and holding food at 41° F or below

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Safety tip: Is your warewasher hot enough?

• Inspect warewashers to make sure water

• Health regulations require that water temperatures in dish machines reach the appropriate temp in orderto properly sanitize ware

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is hot enough to effectively kill bacteria

• Ensuring that the temp reaches the appropriate level also requires a properly operating warewashing system

Safety tip: Calibrate cooking and holding equipment temps

• Routinely calibrate cooking and holding

• Be sure to properly calibrate equipment such as ovens and hot‐food holding cabinets to verify they are cooking and holding at the desired 

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gequipment can help avoid foodborneillnesses

holding at the desired temperatures

• Monitor equipment to make certain that proper temps are maintained at all times and that food is never in the temperature Danger Zone

Safety Tip: Clean Equipment Surfaces

• Thoroughly clean food‐preparationstations and 

• Cleaning equipment surfaces that come into contact with food is one of the first lines of defense against food‐borne illnesses

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equipment to avoid cross‐contamination

borne illnesses• Use food‐prep equipment, 

such as choppers/grinders, slicers and cutter mixers, which are easy to disassemble for cleaning

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Keep them safe…

What is most important to you?

FEBRUARY 16, 2014 Your customers = your success

Preventative MaintenanceYour Ticket to Food Safety

Proactive Care helps you achieve:

• Safe food• Good food quality• A solid customer base

WHAT TO REMEMBER

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Let’s talk numbers

System Service Savings on operating costs

HVAC Cleaning dirty refrigeration coils

25%‐40%

A couple examples of how PM can save you money…

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refrigeration coils

Refrigeration Cleaning dirty refrigeration coils and maintaining refrigeration levels

25%‐60%

Coolers Replacing worn door gaskets

$100 annually

1. Clean all restaurant equipment daily

2. Reference the owner’s manual

Tips for effective preventative maintenance

6. Regularly inspect your restaurant equipment

7. Replace broken or 

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3. Fill out and return the warranty card

4. Educate employees on the proper use of the equipment

5. Perform thorough cleaning on a regular basis

worn out parts8. Be careful with do‐

it‐yourself fixes9. Follow chemical 

instructions10. Properly care for 

stainless steel

A key to improve Sustainabilityand your bottom line is to . . .

Focus on Kitchen Equipment• Lower energy 

consumption• Maximize operational 

efficiency• Ensure the safety of 

your customers

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Q & A

THANK YOU